Reinforced polymer composites from recycled plastic

A structural element, comprising a molded outdoor construction structural element formed from a reinforced polymer composite having:

• from 30 wt % to 35 wt % recycled low-density polyethylene;
• from 15 wt % to 17.5 wt % recycled high-density polyethylene;
• from 15 wt % to 17.5 wt % recycled polypropylene;
• from 15 wt % to 40 wt % glass fibers;
• and
• from 0 wt % to 15 wt % mica filler;
• wherein the mica filler comprises platelets of mica having diameters of between 1 μm and 10 μm.

A method of making a reinforced polymer composite from recycled plastic, comprising the steps of:

• dry mixing pellets of recycled low-density polyethylene, pellets of recycled high-density polyethylene, pellets of recycled polypropylene, glass fibers and mica to form a mixture having:
• from 30 wt % to 35 wt % recycled low-density polyethylene;
• from 15 wt % to 17.5 wt % recycled high-density polyethylene;
• from 15 wt % to 17.5 wt % recycled polypropylene;
• from 15 wt % to 40 wt % glass fibers;
• and
• from 0 wt % to 15 wt % mica filler;
• wherein the mica filler comprises platelets of mica having diameters of between 1 μm and 10 μm;
• feeding the mixture into a twin screw extruder;
• extruding strands of the reinforced polymer composite;
• cooling the extruded strands;
• and
• forming the cooled, extruded strands into pellets of the reinforced polymer composite.